US20150221421A1 - Audio Visual Faceplate with Integrated Hinged Termination Method for Circular Connector - Google Patents
Audio Visual Faceplate with Integrated Hinged Termination Method for Circular Connector Download PDFInfo
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- US20150221421A1 US20150221421A1 US14/607,142 US201514607142A US2015221421A1 US 20150221421 A1 US20150221421 A1 US 20150221421A1 US 201514607142 A US201514607142 A US 201514607142A US 2015221421 A1 US2015221421 A1 US 2015221421A1
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- United States
- Prior art keywords
- connector assembly
- wire cap
- communication
- cap
- cable
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B17/00—Insulators or insulating bodies characterised by their form
- H01B17/38—Fittings, e.g. caps; Fastenings therefor
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/02—Cables with twisted pairs or quads
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/44—Means for preventing access to live contacts
- H01R13/447—Shutter or cover plate
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/62—Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement
- H01R13/629—Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure electrical locking indicators, manufacturing tolerances
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
- H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/22—End caps, i.e. of insulating or conductive material for covering or maintaining connections between wires entering the cap from the same end
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
Definitions
- the present invention relates generally to wiring for audio visual installations and specifically to a wiring solution for audio visual installations that uses 4-twisted pair cabling.
- the AV (audio visual) market is expanding due to increased use of computer graphics and visual telecommunication media in educational, business, healthcare, government, and other applications.
- cable and connector types such as VGA, RCA, 3.5 mm, and digital connections such as HDMI, and these connectors are generally not field terminable.
- Another problem with these solutions is that the connectors generally are not suitable for pulling through an electrical conduit, and consequently are not suitable for a pre-configured solution, i.e., a cable assembly employing such connectors generally are not suitable for pre-assembly offsite and then installation as an assembly at the installed location.
- a communication system has a support and a communication connector attached to the support wherein the connector assembly has a termination lever.
- the system can further include a wire cap connected to a plurality of cable conductors.
- the wire cap can include a cover cap.
- the cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly.
- the support can further include a mounting surface for mounting the communication connector assembly, and the communication connector assembly can include a port for receiving the wire cap and the plurality of cable conductors such that a central axis of the port is non-normal to the front surface. In some embodiments the central axis can be 45° to the front surface.
- the communication connector assembly can further include a plurality of isolated quadrants within the port.
- the wire cap can include at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that the pair inhibits a respective connected conductor release.
- the wire cap includes a divider crossbar and the divider crossbar can include cable posts.
- the support is at least one of a faceplate, a patch panel, a surface mount box, and a media distribution unit.
- a method of connecting a communication cable to a communication connector assembly includes the steps of: wire mapping a plurality of conductors into a wire cap, inserting the wire cap into the communication connector assembly, pressing a termination lever of the communication connector assembly onto the wire cap, and terminating the plurality of conductors into the communication connector assembly.
- the termination step also connects each of the plurality of conductors to respective ones of a plurality of insulation displacement contacts.
- a wire cap for terminating a plurality of conductors of a communication cable to communication connector has at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that at least one the pair having the primary hook is oriented opposite to respective the secondary hook.
- the primary hook and the respective secondary hook inhibit a respective connected the conductor release.
- the wire cap includes a divider crossbar and the divider crossbar can include cable posts.
- a wire cap assembly for terminating a plurality of conductors of a communication cable to communication connector has a wire cap having a termination cap including a plurality of termination slots and a protective cover having integral tabs which align with respective the termination slots.
- the integral tabs inhibit movement of the plurality of conductors.
- a communication system can include a support and a communication connector assembly connected to the support.
- the connector assembly can include a female connector assembly configured for receiving a plurality of cable conductors with a central axis of the female connector assembly being non-normal to the front surface.
- the female connector assembly can further include a plurality of isolated quadrants.
- FIG. 1 is a front isometric view of an audio visual faceplate with an integrated hinged termination method for a circular connector.
- FIG. 2 is a rear isometric view of the audio visual faceplate of FIG. 1
- FIGS. 3 and 4 are exploded views of the faceplate of FIG. 1 .
- FIG. 5 is an isometric view of a circular connector assembly for use with the audio visual faceplate of FIG. 1 .
- FIG. 6 is a front isometric view of the circular connector assembly of FIG. 5 exploded along the central axis.
- FIG. 7 is a rear isometric view of the circular assembly of FIG. 5 exploded along the central axis.
- FIG. 8 is a cross-sectional view of the circular assembly of FIG. 5 .
- FIG. 9 is an isometric view of the circular connector assembly without a pulling cap.
- FIGS. 10 a and 10 b are top views of the circular connector assembly of FIG. 9 ( FIG. 5 without the pulling cap).
- FIG. 11 is a front isometric view of a female connector assembly for use with the audio visual faceplate of FIG. 1 .
- FIG. 12 is a rear isometric view of the female connector assembly of FIG. 11 .
- FIG. 13 is an exploded rear isometric view of the female connector assembly of FIG. 11 .
- FIG. 14 is an exploded side view of the female connector assembly of FIG. 11 .
- FIG. 15 is a top view of the female connector assembly of FIG. 11 with terminated conductors shown.
- FIG. 16 is a bottom view of the female connector assembly of FIG. 11 .
- FIG. 17 is a top view of the circular connector assembly of FIG. 5 mated to the female connector assembly of FIG. 11 .
- FIG. 18 is a cross-sectional view of the mated connectors of FIG. 17 taken along line B-B.
- FIG. 19 is a top view of the mated connector assembly of FIG. 17 showing the keying of the connectors.
- FIG. 20 is a cross-sectional view of the mated connectors of FIG. 17 taken along line C-C of FIG. 19 .
- FIG. 21 is an exploded view of the mated connector assembly of FIG. 17 .
- FIGS. 22 a and 22 b are cross-sectional views of the mated connector assembly of FIG. 17 taken along line D-D of FIG. 21 .
- FIGS. 23 and 24 are rotated rear and side view of the faceplate FIG. 1 with the termination levers in two different orientations.
- FIG. 25 is a front view of a first alternate faceplate.
- FIG. 26 is a rear isometric view of the faceplate of FIG. 25 .
- FIG. 27 is a top level isometric view a second alternate faceplate.
- FIG. 28 is a rear isometric view of the faceplate of FIG. 27 .
- the present invention is a circular connector that utilizes twisted pair cabling that can either be field or factory terminated depending on customer preference, can be fed through conduit with a pull cap without damage to the connector, is fully shielded, and may be utilized in a pre-configured AV solution.
- the present invention utilizes an integrated hinged termination method that provides for a fast termination while securing the connector.
- the connector on the back of the faceplate is angled such that cable management is easier as to not violate cable bend radius requirements.
- FIG. 1 is a front isometric view of communication system 40 , according to the present invention, which includes faceplate assembly 42 connected to wall 44 .
- FIG. 2 is a rear isometric view of communication system 40 (wall 44 has been removed for clarity) in which a circular wire cap assembly 46 is connected to female connector assembly 48 on the rear of faceplate assembly 42 , via termination lever 50 .
- a complete installation patch and/or horizontal cable assemblies typically are installed on the back and front of the faceplate in order to complete communication system 40 , the exclusion of these is not limiting and any form of patching/cabling method may be used to complete the final assembly.
- faceplate assembly 42 front and rear isometrics respectively
- faceplate assembly 42 includes screws 52 , faceplate 54 , connector 56 , circuit board 58 , faceplate backing 60 , keystone RJ45 jack 62 , keystone USB coupler 64 , termination levers 50 , female connector assembly 48 , and circular wire cap assembly 46 .
- Keystone RJ45 jack 62 and keystone USB coupler 64 are shown but may include any non-limiting variety of keystone modules.
- Connector 56 is shown as an HDMI connector; however, other non-limiting connectors may be routed through female connector assembly 48 and circuit board 58 , examples of which include RCA, VGA, DVI, and stereo connectors.
- FIG. 5 is an isometric view of circular wire cap assembly 46 , which is protected by pulling cap 66 .
- FIG. 6 is a front isometric view of circular wire cap assembly 46 and pulling cap 66 that is exploded along central cable axis 68 .
- FIG. 7 is a rear isometric view of circular connector assemblies 46 and pulling cap 66 that is exploded about central cable axis 68 .
- Circular wire cap assembly 46 includes wire termination cap 70 , connecting block 72 , grounding ring 74 , cover cap 76 , and twisted pair cable 78 . Twisted pair cable 78 is shown as a shielded twisted pair cable but termination can be achieved with an unshielded termination cable as well in circular wire cap assembly 46 .
- Pulling cap 66 has tabs 80 that align with termination slots 82 ( FIG. 10 ) on termination cap 70 .
- Termination cap 70 secures to connecting block 72 via latches 84 which align with latch pockets 86 .
- Grounding ring 74 bottoms out on ledge 87 when placed in connecting block 72 .
- Grounding base tabs 88 align with pockets 90 during assembly. Once terminated grounding base tabs 88 deflect and consequently increase in length along central cable axis 68 .
- Recessed pockets 92 on termination cap 70 and recessed pockets 94 on connecting block 72 allow for this extension and prevent grounding base tabs 88 from being tangled during installation or while feeding circular wire cap assembly 46 thru conduit.
- Grounding cable tabs 96 make contact with cable braid 98 during assembly to make the connection between circular wire cap assembly 46 and cable braid 98 .
- Flexible latches 100 on cover cap 76 align with latch pockets 102 on connecting block 72 . Once cover cap 76 is installed it prevents grounding ring 74 from being removed from wire cap assembly 46 .
- Circular wire cap assembly 46 needs to be keyed such that during assembly it is in the correct orientation with respect to female connector assembly 48 .
- slot 104 on termination cap 70 aligns with alignment slot 106 on connecting block 72 which aligns with alignment slot 108 on cover cap 76 .
- Twisted pair cable 78 includes conductors 110 , cable braid 98 , and cable jacket 112 .
- FIG. 8 is a cross-section view of circular wire cap assembly 46 protected by pulling cap 66 . From this view it can be seen that tabs 80 align with termination slots 82 such that conductors 110 are compressed and held in place during installation thru conduit. Also, primary wire hooks 114 can be seen such that conductors 110 are underneath and further hold conductors 110 during installation through conduit.
- FIG. 9 is an isometric view of circular wire cap assembly 46 , (this is similar to FIG. 5 but with pulling cap 66 removed).
- FIG. 10 a and FIG. 10 b is a top view of circular wire cap assembly 46 along central cable axis 68 .
- Conductors 110 align with termination slots 82 , such that each conductor 110 fits into a separate termination slot 82 .
- Both primary wire hooks 114 and secondary wire hooks 116 flex out of the way during conductor 110 assembly and help secure conductors 110 during both install and termination.
- Primary wire hooks 114 and secondary wire hooks 116 flex in opposite directions such that during installation conductor 110 is fed through one hook at a time.
- Cable divider 118 has a twofold purpose in that it controls the depth at which cable 78 is inserted into circular wire cap assembly 46 and separates conductor pairs 110 into individual quadrants 120 . Cable posts 122 on cable divider 118 control the variation in wire cap assembly 46 , by controlling the spacing and orientation of conductor pairs 110 on opposite ends of cable 48 .
- One end of cable 48 is shown in FIG. 10 a and the opposite end of the cable in which conductors 110 need to cross is shown in FIG. 10 b .
- Alternate non-limiting wiring patterns can be achieved through different routings on circuit board 58 .
- Relief slots 124 on termination cap 70 align with grounding spacers 126 on grounding base 128 of female connector assembly 48 .
- FIG. 11 is a front isometric view of female connector assembly 48
- FIG. 12 is a rear isometric view of female connector assembly 48
- Female connector assembly 48 includes grounding base 128 , standoff 130 , and eight IDCs 132 .
- FIG. 13 is an exploded rear isometric view of female connector assembly 48 .
- FIG. 14 is an exploded side view of female connector assembly 48 .
- Grounding base 128 has keying rib 134 which aligns with alignment slot 104 , 106 , and 108 , which insure circular wire cap assembly 46 is correctly aligned with female connector assembly 48 .
- Ledge 136 on grounding base 128 is used for manufacturing purposes such that it gives a flat edge for handling and a place to push on when inserting female connector assembly 48 into circuit board 58 .
- posts 138 on female connector assembly are pressed into circuit board 58 .
- Posts 138 are shown as a solder connection but may be secured to circuit board 58 by other non-limiting ways such as a press fit.
- Cutout 140 on grounding base 128 and cutoff 142 on standoff 130 shorten the overall length of the connector assembly 48 which saves space on circuit board 58 .
- Support ribs 144 on standoff 130 support IDCs 132 from buckling when compliant pins 146 of IDCs 132 are pressed into circuit board 58 .
- IDCs 132 are shown with compliant pins 146 for being secured to the circuit board but may use other non-limiting ways of being secured to the circuit board such as soldering.
- Grounding spacers 126 on grounding base 128 align with relief slots 124 on termination cap 70 such that each pair of conductors 110 is isolated during termination from the adjacent pair of conductors 110 .
- Grounding spacers 126 are angled towards the center to allow for the end to end effect of twisted pair cables and let pairs of conductors 110 crossover on opposite ends of female connector assembly 48 .
- Grounding bars 148 of grounding base 128 are below surface 150 (see FIG. 15 ) of standoff 130 , and isolate IDC pairs 132 from each other similar to how grounding spacers 126 isolate conductor pairs 110 above surface 150 .
- Center divider 152 of grounding base 128 creates a uniform spacing between ground and IDC pairs 132 .
- IDCs 132 are a mirror image about datum 154 (shown as cross-section B-B of FIG. 17 ), so as to keep a uniform spacing to ground and reduce the amount of unique components within female connector assembly 48 .
- Cutouts 156 on standoff 130 align with grounding spacers 126
- cutouts 158 align with grounding bars 148 to allow for clearance between standoff 130 and grounding base 128 .
- FIG. 15 is a top view of female connector assembly 48 ; this is the same orientation as circular wire cap assembly 46 would be installed along central cable axis 68 .
- FIG. 15 shows the isolation of pairs of conductors 110 due to grounding spacers 126 .
- FIG. 16 is a bottom view of female connector assembly 48 ; this is the same orientation as circular wire cap assembly 46 is installed along central cable axis 68 . This is also the orientation in which standoff 130 is loaded into grounding base 128 , and IDCs 132 are loaded into standoff 30 along central cable axis 68 to complete female connector assembly 48 . Cutouts 160 in standoff 130 allow for posts 138 to not interfere during assembly. Ribs 162 add material between grounding base 128 and IDCs 132 so as to reduce chances of failure during dielectric withstand voltage or “Hipot” testing.
- FIG. 17 is a top view of female connector assembly 48 and circular wire cap assembly 46 .
- FIG. 18 is a cross-section B-B from FIG. 17 of the assembly of female connector assembly 48 and circular wire cap assembly 46 .
- FIG. 18 view further demonstrates the isolation of pair of conductors 110 due to grounding spacers 126 , and also shows the relative space in the center of grounding spacers 126 due to the angled center to allow for crossover pairs on opposite ends of female connector assembly 48 .
- FIG. 19 is a top view that demonstrates how female connector assembly 48 is keyed during the installation of circular wire cap assembly 46 via keying rib 134 which aligns with alignment slots 104 , 106 , and 108 .
- FIG. 20 is a cross-section C-C from FIG. 19 of the assembly of female connector assembly 48 and circular wire cap assembly 46 .
- This view illustrates the full electrically bonded path between shielded braid 98 of twisted pair cable 78 and posts 138 of grounding base 128 .
- Grounding cable tabs 96 of grounding ring 74 make contact with braid 98 of twisted pair cable 78 at contact point 164 .
- Grounding base tabs 88 of grounding ring 74 make contact with grounding base 128 at contact point 166 .
- Posts 138 of grounding base 128 connect to circuit board 58 (for clarity circuit board 58 is not shown in FIG. 19 ) thus completing the full path to ground.
- FIG. 21 is an exploded view of female connector assembly 48 and circular wire cap assembly 46 .
- FIG. 22 a and FIG. 22 b are cross-section views of FIG. 21 about Section D-D in which FIG. 22 a and FIG. 22 b show circular wire cap assembly 46 assembled with opposite ends (two scenarios) of cable 78 . These views further show how grounding spacers 126 is angled center to allow for crossover pairs on opposite ends of female connector assembly 48 , while still maintaining electrical isolation.
- FIG. 23 is a rotated rear and side views of faceplate assembly 42 , with termination levers 50 in two different orientations. Termination lever 50 a is in the unloaded position, and termination lever 50 b is the position needed to insert circular wire cap assembly 46 through large slot 168 of termination lever 50 . Termination lever 50 rotates about hinge 170 , and is secured by hook 172 .
- FIG. 24 is a rotated view of communication system 40 and its projection, with termination levers 50 in two different orientations. Termination lever 50 a is in the unloaded position, and termination lever 50 b is in the terminated position.
- Termination lever 50 is rotated such that the bottom surface pushes on cover cap 76 of circular wire cap assembly 46 in order to generate the force needed such that IDCs 132 make electrical contact with conductors 110 .
- twisted pair cable 78 passes through small slot 173 without interference.
- flexible latch 176 In order to insure a complete termination lip 174 must clear flexible latch 176 , which forces termination cap 70 to bottom out on surface 150 of standoff 130 .
- FIG. 25 is a front isometric view of communication system 178 according to a first alternate embodiment of the present invention.
- FIG. 26 is a rear isometric view of communication system 178 .
- Communication system 178 replaces faceplate backing 60 with faceplate backing 180 , and faceplate 54 with faceplate 179 , and no longer has an option for mounting of keystone modules.
- FIG. 27 is a top level isometric view of a second alternate embodiment showing communication system 182 .
- FIG. 28 is a rear isometric view of communication system 182 .
- Communication system 182 is shown paired with a GFCI faceplate 184 populated with RJ45 modules 186 which is mounted to double gang faceplate 188 .
- RJ45 modules 186 are shown paired with a GFCI faceplate, system 182 can include other faceplate backing 60 or 180 in any non-limiting combination.
- Modules 186 are shown as Panduit Mini-Com RJ45 network jacks however they may have included any non-limiting modules examples of which include USB, Fiber, AV modules, and others.
- the present invention has been shown as a fully shielded assembly; however, in many applications shielding may not be required so in order to reduce the amount of components and end cost of the assembly, the solution can be used as an unshielded solution.
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Abstract
A communication system has a support and a communication connector attached to the support wherein the connector assembly has a termination lever. The system can further include a wire cap connected to a plurality of cable conductors. The wire cap can include a cover cap. The cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly. The support can be one of a faceplate, a patch panel, a surface mount box, or a media distribution unit.
Description
- This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/934,234, filed Jan. 31, 2014 and U.S. Provisional Patent Application Ser. No. 62/031,927, filed Aug. 1, 2014, which are incorporated herein by reference in their entirety.
- The present invention relates generally to wiring for audio visual installations and specifically to a wiring solution for audio visual installations that uses 4-twisted pair cabling.
- The AV (audio visual) market is expanding due to increased use of computer graphics and visual telecommunication media in educational, business, healthcare, government, and other applications. There are a variety of cable and connector types such as VGA, RCA, 3.5 mm, and digital connections such as HDMI, and these connectors are generally not field terminable. Another problem with these solutions is that the connectors generally are not suitable for pulling through an electrical conduit, and consequently are not suitable for a pre-configured solution, i.e., a cable assembly employing such connectors generally are not suitable for pre-assembly offsite and then installation as an assembly at the installed location.
- In one embodiment, a communication system has a support and a communication connector attached to the support wherein the connector assembly has a termination lever.
- In some embodiments, the system can further include a wire cap connected to a plurality of cable conductors. The wire cap can include a cover cap.
- In some embodiments, the cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly.
- In some embodiments, the support can further include a mounting surface for mounting the communication connector assembly, and the communication connector assembly can include a port for receiving the wire cap and the plurality of cable conductors such that a central axis of the port is non-normal to the front surface. In some embodiments the central axis can be 45° to the front surface.
- In some embodiments, the communication connector assembly can further include a plurality of isolated quadrants within the port.
- In some embodiments, the wire cap can include at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that the pair inhibits a respective connected conductor release.
- In some embodiments, the wire cap includes a divider crossbar and the divider crossbar can include cable posts.
- In some embodiments, the support is at least one of a faceplate, a patch panel, a surface mount box, and a media distribution unit.
- In one embodiment, a method of connecting a communication cable to a communication connector assembly includes the steps of: wire mapping a plurality of conductors into a wire cap, inserting the wire cap into the communication connector assembly, pressing a termination lever of the communication connector assembly onto the wire cap, and terminating the plurality of conductors into the communication connector assembly.
- In some embodiments, the termination step also connects each of the plurality of conductors to respective ones of a plurality of insulation displacement contacts.
- In one embodiment, a wire cap for terminating a plurality of conductors of a communication cable to communication connector has at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors such that at least one the pair having the primary hook is oriented opposite to respective the secondary hook.
- In some embodiments, the primary hook and the respective secondary hook inhibit a respective connected the conductor release.
- In some embodiments, the wire cap includes a divider crossbar and the divider crossbar can include cable posts.
- In one embodiment, a wire cap assembly for terminating a plurality of conductors of a communication cable to communication connector has a wire cap having a termination cap including a plurality of termination slots and a protective cover having integral tabs which align with respective the termination slots.
- In some embodiments, the integral tabs inhibit movement of the plurality of conductors.
- In one embodiment, a communication system can include a support and a communication connector assembly connected to the support. The connector assembly can include a female connector assembly configured for receiving a plurality of cable conductors with a central axis of the female connector assembly being non-normal to the front surface. The female connector assembly can further include a plurality of isolated quadrants.
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FIG. 1 is a front isometric view of an audio visual faceplate with an integrated hinged termination method for a circular connector. -
FIG. 2 is a rear isometric view of the audio visual faceplate ofFIG. 1 -
FIGS. 3 and 4 are exploded views of the faceplate ofFIG. 1 . -
FIG. 5 is an isometric view of a circular connector assembly for use with the audio visual faceplate ofFIG. 1 . -
FIG. 6 is a front isometric view of the circular connector assembly ofFIG. 5 exploded along the central axis. -
FIG. 7 is a rear isometric view of the circular assembly ofFIG. 5 exploded along the central axis. -
FIG. 8 is a cross-sectional view of the circular assembly ofFIG. 5 . -
FIG. 9 is an isometric view of the circular connector assembly without a pulling cap. -
FIGS. 10 a and 10 b are top views of the circular connector assembly ofFIG. 9 (FIG. 5 without the pulling cap). -
FIG. 11 is a front isometric view of a female connector assembly for use with the audio visual faceplate ofFIG. 1 . -
FIG. 12 is a rear isometric view of the female connector assembly ofFIG. 11 . -
FIG. 13 is an exploded rear isometric view of the female connector assembly ofFIG. 11 . -
FIG. 14 is an exploded side view of the female connector assembly ofFIG. 11 . -
FIG. 15 is a top view of the female connector assembly ofFIG. 11 with terminated conductors shown. -
FIG. 16 is a bottom view of the female connector assembly ofFIG. 11 . -
FIG. 17 is a top view of the circular connector assembly ofFIG. 5 mated to the female connector assembly ofFIG. 11 . -
FIG. 18 is a cross-sectional view of the mated connectors ofFIG. 17 taken along line B-B. -
FIG. 19 is a top view of the mated connector assembly ofFIG. 17 showing the keying of the connectors. -
FIG. 20 is a cross-sectional view of the mated connectors ofFIG. 17 taken along line C-C ofFIG. 19 . -
FIG. 21 is an exploded view of the mated connector assembly ofFIG. 17 . -
FIGS. 22 a and 22 b are cross-sectional views of the mated connector assembly ofFIG. 17 taken along line D-D ofFIG. 21 . -
FIGS. 23 and 24 are rotated rear and side view of the faceplateFIG. 1 with the termination levers in two different orientations. -
FIG. 25 is a front view of a first alternate faceplate. -
FIG. 26 is a rear isometric view of the faceplate ofFIG. 25 . -
FIG. 27 is a top level isometric view a second alternate faceplate. -
FIG. 28 is a rear isometric view of the faceplate ofFIG. 27 . - The present invention is a circular connector that utilizes twisted pair cabling that can either be field or factory terminated depending on customer preference, can be fed through conduit with a pull cap without damage to the connector, is fully shielded, and may be utilized in a pre-configured AV solution. The present invention utilizes an integrated hinged termination method that provides for a fast termination while securing the connector. The connector on the back of the faceplate is angled such that cable management is easier as to not violate cable bend radius requirements.
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FIG. 1 is a front isometric view ofcommunication system 40, according to the present invention, which includesfaceplate assembly 42 connected towall 44.FIG. 2 is a rear isometric view of communication system 40 (wall 44 has been removed for clarity) in which a circularwire cap assembly 46 is connected tofemale connector assembly 48 on the rear offaceplate assembly 42, viatermination lever 50. In a complete installation patch and/or horizontal cable assemblies typically are installed on the back and front of the faceplate in order to completecommunication system 40, the exclusion of these is not limiting and any form of patching/cabling method may be used to complete the final assembly. - Referring now to
FIG. 3 andFIG. 4 , exploded views of faceplate assembly 42 (front and rear isometrics respectively) includesscrews 52,faceplate 54,connector 56,circuit board 58,faceplate backing 60,keystone RJ45 jack 62,keystone USB coupler 64, termination levers 50,female connector assembly 48, and circularwire cap assembly 46.Keystone RJ45 jack 62 andkeystone USB coupler 64 are shown but may include any non-limiting variety of keystone modules.Connector 56 is shown as an HDMI connector; however, other non-limiting connectors may be routed throughfemale connector assembly 48 andcircuit board 58, examples of which include RCA, VGA, DVI, and stereo connectors. -
FIG. 5 is an isometric view of circularwire cap assembly 46, which is protected by pullingcap 66.FIG. 6 is a front isometric view of circularwire cap assembly 46 and pullingcap 66 that is exploded alongcentral cable axis 68.FIG. 7 is a rear isometric view ofcircular connector assemblies 46 and pullingcap 66 that is exploded aboutcentral cable axis 68. Circularwire cap assembly 46 includeswire termination cap 70, connectingblock 72, groundingring 74,cover cap 76, andtwisted pair cable 78.Twisted pair cable 78 is shown as a shielded twisted pair cable but termination can be achieved with an unshielded termination cable as well in circularwire cap assembly 46. Pullingcap 66 hastabs 80 that align with termination slots 82 (FIG. 10 ) ontermination cap 70.Termination cap 70 secures to connectingblock 72 vialatches 84 which align with latch pockets 86. Groundingring 74 bottoms out onledge 87 when placed in connectingblock 72. Groundingbase tabs 88 align withpockets 90 during assembly. Once terminatedgrounding base tabs 88 deflect and consequently increase in length alongcentral cable axis 68. Recessed pockets 92 ontermination cap 70 and recessedpockets 94 on connectingblock 72 allow for this extension and preventgrounding base tabs 88 from being tangled during installation or while feeding circularwire cap assembly 46 thru conduit. Groundingcable tabs 96 make contact withcable braid 98 during assembly to make the connection between circularwire cap assembly 46 andcable braid 98. Flexible latches 100 oncover cap 76 align with latch pockets 102 on connectingblock 72. Oncecover cap 76 is installed it prevents groundingring 74 from being removed fromwire cap assembly 46. Circularwire cap assembly 46 needs to be keyed such that during assembly it is in the correct orientation with respect tofemale connector assembly 48. In order to accomplish this alignment,slot 104 ontermination cap 70 aligns withalignment slot 106 on connectingblock 72 which aligns withalignment slot 108 oncover cap 76.Twisted pair cable 78 includesconductors 110,cable braid 98, andcable jacket 112. -
FIG. 8 is a cross-section view of circularwire cap assembly 46 protected by pullingcap 66. From this view it can be seen thattabs 80 align withtermination slots 82 such thatconductors 110 are compressed and held in place during installation thru conduit. Also, primary wire hooks 114 can be seen such thatconductors 110 are underneath and further holdconductors 110 during installation through conduit. -
FIG. 9 is an isometric view of circularwire cap assembly 46, (this is similar toFIG. 5 but with pullingcap 66 removed).FIG. 10 a andFIG. 10 b is a top view of circularwire cap assembly 46 alongcentral cable axis 68.Conductors 110 align withtermination slots 82, such that eachconductor 110 fits into aseparate termination slot 82. Both primary wire hooks 114 and secondary wire hooks 116 flex out of the way duringconductor 110 assembly and helpsecure conductors 110 during both install and termination. Primary wire hooks 114 and secondary wire hooks 116 flex in opposite directions such that duringinstallation conductor 110 is fed through one hook at a time. Primary wire hooks 114 and secondary wire hooks 116 are in opposite directions to insure that noconductor 110 falls out ofwire slot 82 during installation.Cable divider 118 has a twofold purpose in that it controls the depth at whichcable 78 is inserted into circularwire cap assembly 46 and separates conductor pairs 110 intoindividual quadrants 120. Cable posts 122 oncable divider 118 control the variation inwire cap assembly 46, by controlling the spacing and orientation of conductor pairs 110 on opposite ends ofcable 48. One end ofcable 48 is shown inFIG. 10 a and the opposite end of the cable in whichconductors 110 need to cross is shown inFIG. 10 b. Alternate non-limiting wiring patterns can be achieved through different routings oncircuit board 58.Relief slots 124 ontermination cap 70 align withgrounding spacers 126 on groundingbase 128 offemale connector assembly 48. -
FIG. 11 is a front isometric view offemale connector assembly 48, andFIG. 12 is a rear isometric view offemale connector assembly 48.Female connector assembly 48 includes groundingbase 128,standoff 130, and eightIDCs 132.FIG. 13 is an exploded rear isometric view offemale connector assembly 48.FIG. 14 is an exploded side view offemale connector assembly 48. Groundingbase 128 has keyingrib 134 which aligns withalignment slot wire cap assembly 46 is correctly aligned withfemale connector assembly 48.Ledge 136 on groundingbase 128 is used for manufacturing purposes such that it gives a flat edge for handling and a place to push on when insertingfemale connector assembly 48 intocircuit board 58. In order to complete the ground connection betweenfemale connector assembly 48 andcircuit board 58,posts 138 on female connector assembly are pressed intocircuit board 58.Posts 138 are shown as a solder connection but may be secured tocircuit board 58 by other non-limiting ways such as a press fit.Cutout 140 on groundingbase 128 andcutoff 142 onstandoff 130 shorten the overall length of theconnector assembly 48 which saves space oncircuit board 58.Support ribs 144 onstandoff 130support IDCs 132 from buckling whencompliant pins 146 ofIDCs 132 are pressed intocircuit board 58.IDCs 132 are shown withcompliant pins 146 for being secured to the circuit board but may use other non-limiting ways of being secured to the circuit board such as soldering. Grounding spacers 126 on groundingbase 128 align withrelief slots 124 ontermination cap 70 such that each pair ofconductors 110 is isolated during termination from the adjacent pair ofconductors 110. Groundingspacers 126 are angled towards the center to allow for the end to end effect of twisted pair cables and let pairs ofconductors 110 crossover on opposite ends offemale connector assembly 48. Grounding bars 148 ofgrounding base 128 are below surface 150 (seeFIG. 15 ) ofstandoff 130, and isolate IDC pairs 132 from each other similar to how grounding spacers 126 isolate conductor pairs 110 abovesurface 150.Center divider 152 ofgrounding base 128 creates a uniform spacing between ground and IDC pairs 132.IDCs 132 are a mirror image about datum 154 (shown as cross-section B-B ofFIG. 17 ), so as to keep a uniform spacing to ground and reduce the amount of unique components withinfemale connector assembly 48.Cutouts 156 onstandoff 130 align withgrounding spacers 126, andcutouts 158 align with groundingbars 148 to allow for clearance betweenstandoff 130 andgrounding base 128. -
FIG. 15 is a top view offemale connector assembly 48; this is the same orientation as circularwire cap assembly 46 would be installed alongcentral cable axis 68.FIG. 15 shows the isolation of pairs ofconductors 110 due to groundingspacers 126.FIG. 16 is a bottom view offemale connector assembly 48; this is the same orientation as circularwire cap assembly 46 is installed alongcentral cable axis 68. This is also the orientation in whichstandoff 130 is loaded intogrounding base 128, andIDCs 132 are loaded into standoff 30 alongcentral cable axis 68 to completefemale connector assembly 48.Cutouts 160 instandoff 130 allow forposts 138 to not interfere during assembly.Ribs 162 add material betweengrounding base 128 andIDCs 132 so as to reduce chances of failure during dielectric withstand voltage or “Hipot” testing. -
FIG. 17 is a top view offemale connector assembly 48 and circularwire cap assembly 46.FIG. 18 is a cross-section B-B fromFIG. 17 of the assembly offemale connector assembly 48 and circularwire cap assembly 46.FIG. 18 view further demonstrates the isolation of pair ofconductors 110 due to groundingspacers 126, and also shows the relative space in the center of groundingspacers 126 due to the angled center to allow for crossover pairs on opposite ends offemale connector assembly 48.FIG. 19 is a top view that demonstrates howfemale connector assembly 48 is keyed during the installation of circularwire cap assembly 46 via keyingrib 134 which aligns withalignment slots -
FIG. 20 is a cross-section C-C fromFIG. 19 of the assembly offemale connector assembly 48 and circularwire cap assembly 46. This view illustrates the full electrically bonded path between shieldedbraid 98 of twistedpair cable 78 andposts 138 ofgrounding base 128. Groundingcable tabs 96 of groundingring 74 make contact withbraid 98 of twistedpair cable 78 atcontact point 164. Groundingbase tabs 88 of groundingring 74 make contact withgrounding base 128 atcontact point 166.Posts 138 ofgrounding base 128 connect to circuit board 58 (forclarity circuit board 58 is not shown inFIG. 19 ) thus completing the full path to ground. -
FIG. 21 is an exploded view offemale connector assembly 48 and circularwire cap assembly 46.FIG. 22 a andFIG. 22 b are cross-section views ofFIG. 21 about Section D-D in whichFIG. 22 a andFIG. 22 b show circularwire cap assembly 46 assembled with opposite ends (two scenarios) ofcable 78. These views further show how grounding spacers 126 is angled center to allow for crossover pairs on opposite ends offemale connector assembly 48, while still maintaining electrical isolation. -
FIG. 23 is a rotated rear and side views offaceplate assembly 42, withtermination levers 50 in two different orientations.Termination lever 50 a is in the unloaded position, andtermination lever 50 b is the position needed to insert circularwire cap assembly 46 throughlarge slot 168 oftermination lever 50.Termination lever 50 rotates abouthinge 170, and is secured byhook 172.FIG. 24 is a rotated view ofcommunication system 40 and its projection, withtermination levers 50 in two different orientations.Termination lever 50 a is in the unloaded position, andtermination lever 50 b is in the terminated position.Termination lever 50 is rotated such that the bottom surface pushes oncover cap 76 of circularwire cap assembly 46 in order to generate the force needed such thatIDCs 132 make electrical contact withconductors 110. Once circularwire cap assembly 46 is terminated, twistedpair cable 78 passes throughsmall slot 173 without interference. In order to insure acomplete termination lip 174 must clearflexible latch 176, which forcestermination cap 70 to bottom out onsurface 150 ofstandoff 130. - As described above, the present invention can have mounting options for keystone modules.
FIG. 25 is a front isometric view ofcommunication system 178 according to a first alternate embodiment of the present invention.FIG. 26 is a rear isometric view ofcommunication system 178.Communication system 178 replacesfaceplate backing 60 withfaceplate backing 180, andfaceplate 54 withfaceplate 179, and no longer has an option for mounting of keystone modules. - The present invention has been shown used in single gang faceplates only, however this solution may be used in any non-limiting gang of faceplates.
FIG. 27 is a top level isometric view of a second alternate embodiment showingcommunication system 182.FIG. 28 is a rear isometric view ofcommunication system 182.Communication system 182 is shown paired with aGFCI faceplate 184 populated withRJ45 modules 186 which is mounted todouble gang faceplate 188. Althoughcommunication systems 182 is shown paired with a GFCI faceplate,system 182 can include other faceplate backing 60 or 180 in any non-limiting combination.Modules 186 are shown as Panduit Mini-Com RJ45 network jacks however they may have included any non-limiting modules examples of which include USB, Fiber, AV modules, and others. - The present invention has been shown as a fully shielded assembly; however, in many applications shielding may not be required so in order to reduce the amount of components and end cost of the assembly, the solution can be used as an unshielded solution.
- While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing without departing from the spirit and scope of the invention as described.
Claims (20)
1. A communication system, comprising:
a support; and
a communication connector assembly connected to the support, the connector assembly including a termination lever.
2. The communication system of claim 1 , further including a wire cap connected to a plurality of cable conductors, the termination lever for terminating the wire cap and the plurality of cable conductors to the communication connector assembly.
3. The communication system of claim 2 , wherein the wire cap includes a cover cap.
4. The communication system of claim 3 , wherein the cover cap latches to the connector assembly when the wire cap and the plurality of cable conductors is terminated to the communication connector assembly.
5. The communication system of claim 2 , wherein the support further includes a mounting surface for mounting the communication connector assembly, the communication connector assembly includes a port for receiving the wire cap and the plurality of cable conductors, and a central axis of the port is non-normal to the front surface.
6. The communication system of claim 5 , wherein the central axis of the port is approximately 45° to the front surface.
7. The communication system of claim 5 , wherein the communication connector assembly further includes a plurality of isolated quadrants within the port.
8. The communication system of claim 2 , wherein the wire cap includes at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors, the at least one pair having the primary hook oriented opposite to the respective secondary hook and inhibiting a respective connected conductor release.
9. The communication system of claim 2 , wherein the wire cap includes a divider crossbar.
10. The communication system of claim 9 , wherein the divider crossbar includes cable posts.
11. The communication system of claim 1 , wherein the support is at least one of a faceplate, a patch panel, a surface mount box, or a media distribution unit.
12. A method of connecting a communication cable to a communication connector assembly, the method comprising the steps of:
wire mapping a plurality of conductors into a wire cap;
inserting the wire cap into the communication connector assembly;
pressing a termination lever of the communication connector assembly onto the wire cap; and
terminating the plurality of conductors into the communication connector assembly.
13. The method of claim 12 , wherein the terminating step connects each of the plurality of conductors to respective ones of a plurality of insulation displacement contacts.
14. A wire cap for terminating a plurality of conductors of a communication cable to communication connector, the wire cap comprising:
at least one pair of a primary hook and a respective secondary hook for at least one of the plurality of cable conductors, wherein the primary hook of the at least one pair is oriented opposite to the respective secondary hook.
15. The wire cap of claim 14 , wherein the primary hook and the respective secondary hook inhibit a respective connected conductor release.
16. The wire cap of claim 14 , wherein the wire cap includes a divider crossbar.
17. The wire cap of claim 16 , wherein the divider crossbar includes cable posts.
18. A wire cap assembly for terminating a plurality of conductors of a communication cable to a communication connector, the wire cap assembly comprising:
a wire cap having a termination cap including a plurality of termination slots;
a protective cover having integral tabs which align with respective the termination slots.
19. The wire cap assembly of claim 18 , wherein the integral tabs inhibit movement of the plurality of conductors.
20. A communication system, comprising:
a support; and
a communication connector assembly connected to the support, the connector assembly including a female connector assembly configured for receiving a plurality of cable conductors, a central axis of the female connector assembly being non-normal to the front surface, the female connector assembly further including a plurality of isolated quadrants.
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US14/607,142 US9520692B2 (en) | 2014-01-31 | 2015-01-28 | Audio visual faceplate with integrated hinged termination method for circular connector |
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US201461934234P | 2014-01-31 | 2014-01-31 | |
US201462031927P | 2014-08-01 | 2014-08-01 | |
US14/607,142 US9520692B2 (en) | 2014-01-31 | 2015-01-28 | Audio visual faceplate with integrated hinged termination method for circular connector |
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US20150221421A1 true US20150221421A1 (en) | 2015-08-06 |
US9520692B2 US9520692B2 (en) | 2016-12-13 |
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US11482352B2 (en) * | 2018-01-09 | 2022-10-25 | Ubiquiti Inc. | Quick connecting twisted pair cables |
US11626688B2 (en) | 2020-05-29 | 2023-04-11 | Panduit Corp. | Field terminable cable and plug assembly |
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USRE49785E1 (en) * | 2013-10-23 | 2024-01-02 | Endress+Hauser Flowtec Ag | Connector apparatus for a field device as well as field device with such a connector apparatus |
US20200313413A1 (en) * | 2017-03-07 | 2020-10-01 | CommScope Connectivity Belgium BVBA | Cable grounding assembly for telecommunications enclosure |
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